Case Study: E-Houses Powering Sustainability – Enabling Flared Gas Recovery for Clean Power Generation & New Revenue Streams

Project Brief

Project Name: Containerized E Houses for Electrical Infrastructure Expansion to enhance Gas Processing Capacity at NGL facility

Client Name: Undisclosed

Location: Middle East

Industry: Gas Processing/Gas Liquefaction

Facility:

Greenfield gas processing units for processing captured flared gas that will be utilized for power generation and feeding the NGL facility housed at one of the largest ‘supergiant’ oil fields in the world.

Customer's question

The client launched a strategic initiative to reduce gas flaring and cut 6–10 million tons of CO? annually. Their NGL facility plays a key role by utilizing flared gas to supply the national grid with additional electricity and local markets with associated products.

As part of its expansion, two new processing trains, each handling 200 MMscf/d, were planned. This will boost total gas processing capacity from 1 Bcf/d to 1.4 Bcf/d.

To support these goals, a reliable engineering partner was sought to provide LV/MV electrical distribution system to ensure uninterrupted power for the trains, enhancing operational efficiency, reliability, and power generation capacity.

Benefits Delivered

• Enabled client’s objectives of reducing carbon footprint while increasing processing capacity by 40%, generating 1900MW of clean electricity, and new revenue streams for the local economy.
• Delivered a plug-and-play, pre-designed, and pre-tested E-Houses solution guaranteeing continuous and uninterrupted power in operationally challenging conditions and customized to the client’s specific needs. This approach minimized on-site construction, resulting in significant cost and time savings, and ensuring on-time and within-budget project delivery.
• Simplified the procurement and integration process by acting as a single point of contact, streamlining multi-OEM equipment management for the client while taking on the additional complex scope of OEM supplied substations commissioning.
• Leveraged advanced 3D modeling to resolve space constraints for the clients and integrate multiple complex equipment, ensuring neatly routed cables and an optimized layout that not only enhanced space efficiency but also transparency and client’s understanding of INTECH’s project execution methodology.
• Maintaining a zero-incident safety record, INTECH prioritized and proactively implemented the highest safety standards, ensuring personnel well-being and equipment protection in challenging conditions.

Detailed Scope of Work

INTECH’s initial scope included the end-to-end design, manufacturing, testing, and commissioning of four substations for the main process plant to support electrical distribution requirements. During the project, the customer faced challenges in commissioning three substations from another OEM. Based on INTECH’s performance in commissioning of inside Battery Limits (ISBL) substations, INTECH’s scope was expanded to include the commissioning of these additional three Outside Battery Limits (OSBL) substations.

INTECH’s scope included:

A. End-to-end Design and Engineering of 4 ISBL Substations

End-to-end design and detailed engineering of electrical distribution systems of 4 substations (ISBL):

• Two E-Houses equipped with 11kV MV Switchgear, 0.4kV LV Switchgear, Auxiliary Panels, MV VFD, Fire Alarm Control Panels, Lighting System, Cable Trays/Raceway Systems, and a Ventilation System.
• Two emergency power switchgear E-buildings featuring 11kV MV Switchgear, Redundant AC/DC UPS Systems with Batteries & Distribution Boards (DB), Fire Alarm Control Panels, Lighting System, Cable Trays/Raceway Systems, and a Ventilation System.
• Integration, internal testing, and integrated FAT
• On-site testing, pre-commissioning & commissioning of all electrical systems

B. Commissioning of 3 OSBL Substations:

Testing & commissioning of three OSBL substations equipped with LV/MV switchgear, AC UPS systems, DC UPS systems, HVAC, and FACP.

E-House Structure and System Details

Construction: Fully welded and painted structures spanning over 600 square meters, the E-Houses were designed as non-fire-rated units, divided into two sections.

• Dimensions: Each section measured 32m x 5m x 5m, with a total external footprint of 32m x 10m x 5m.

Design: Engineered to accommodate all necessary systems and components while ensuring an optimal operational environment.

Installed Systems & Components

Electrical Systems:

• 0.4kV LV Switchgear
• 11kV MV Switchgear
• Auxiliary Panels, including Interposing Relay and Remote-Control Panel for MTS
• MV VFD System (11kV VFD panel for 298KW, 3.3kV motor)
• 11 outgoing motor feeders
• Redundant AC/DC UPS Systems with Batteries and Distribution Boards (DB)

Safety & Support Systems:

• Fire Alarm Control Panel
• Lighting Systems
• Cable Trays & Raceway Systems
• HVAC System

Each E-House was designed with dedicated safety and operational support systems, ensuring reliable, secure, and efficient electrical infrastructure for the gas processing plant.

Challenges & Solutions

Complexity of Electrical Infrastructure

Space constraint:

Integrating multiple complex systems within a limited E-House space was a significant challenge. Each system required dedicated space, safety zones, proper ventilation, and accessibility for future maintenance. The proximity of critical equipment introduced safety and operational risks, including overheating and maintenance difficulties. Additionally, neat and organized cabling was required to ensure long-term system reliability and ease of maintenance after handover to the client.

System complexity:

Tailoring E-house designs according to client requirements required integrating diverse OEM electrical systems. This demanded deep technical expertise and specialized knowledge to manage their unique testing and commissioning needs.

Solution

Optimized Space Utilization Through Advanced 3D Modeling:

To overcome the challenge of integrating multiple complex systems within a limited E-House space, INTECH employed detailed Advanced 3D modeling. This enabled the team to manage precise equipment placement, ensuring dedicated space for each system while maintaining critical safety zones and proper ventilation. By visualizing the entire layout in 3D, INTECH proactively mitigated potential safety and operational risks associated with equipment proximity, such as overheating and maintenance difficulties.

Furthermore, the 3D model facilitated structured cable management and efficient wiring routing. This approach guaranteed neat and organized cabling, which is crucial for long-term system reliability and streamlined maintenance post-handover. By strategic planning and executing the design based on the 3D model, INTECH maximized space utilization while prioritizing safety, accessibility, and ease of maintenance.

Multi OEM systems Expertise:

With deep technical knowledge and extensive multi-vendor OEM systems Expertise, INTECH's in-house team expertly managed the integration of diverse OEM systems, implementing a structured design, testing, and commissioning process, ensuring optimal performance and functionality.

Multi-OEM Environment

The project required the integration and commissioning of a wide range of electrical systems and equipment from multiple OEMs within a confined substation area. Each equipment had distinct operational and safety requirements. Testing and commissioning these systems simultaneously in a restricted workspace added significant complexity.

Additionally, managing procurement for various OEM equipment while aligning lead times, delivery schedules, and technical specifications was a critical challenge. Ensuring seamless coordination among multiple vendors, subcontractors, the Commissioning & Start-Up team, and the end-user required a single point of contact to prevent bottlenecks and delays.

Solution

INTECH streamlined the procurement process by clearly defining operational requirements and specifications for each OEM. Leveraging an extensive procurement network and strong OEM relationships, INTECH ensured close collaboration with vendors for timely deliveries, preventing disruptions in integration and commissioning. Acting as the single point of contact, INTECH managed all communication with OEMs, ensuring on-time equipment delivery to avoid project delays.

Given the limited workspace, INTECH implemented a structured approach for testing and commissioning, prioritizing critical systems, and minimizing risks.

Through structured coordination, optimized workspace management, and a proactive procurement strategy, INTECH successfully executed the project, overcoming the complexities of a multi-OEM environment within a constrained space.

Commissioning of OEM-manufactured OSBL substations

Commissioning OEM-manufactured OSBL substations presented unique challenges that could significantly impact project timelines, operational reliability, and safety. These include:

ATS Operational Failure:

The automatic transfer switch (ATS) failed to operate as expected, posing a risk to power reliability and system continuity. This could have resulted in operational delays, compromised system uptime, and potential safety concerns.

MV Switchgear-Transformer Interface Error

Communication failures between the MV switchgear and the transformer created operational inconsistencies, potentially leading to faults, system malfunctions, and equipment damage.

Energization and Load Testing Complexities

Incomplete pre-energization checks and incorrect parameter settings in protection relays introduced significant risks, including potential equipment damage, unexpected shutdowns, and prolonged commissioning delays.

Solution

INTECH's expertise and proactive approach ensured successful commissioning by overcoming these challenges and delivering reliable, high-performance substations:

ATS Operation Optimization

INTECH's team conducted an in-depth analysis of relay logic and project operation philosophy. Discrepancies were identified, and the necessary logic modifications and parameter reconfigurations were implemented, all without OEM intervention. This ensured smooth and reliable ATS operation, meeting client expectations for power reliability and system continuity.

MV Switchgear-Transformer Interface Integrity

INTECH conducted detailed troubleshooting, meticulously tracing and verifying all wiring connections, and performed cold loop checks to identify and rectify errors. Missing signals were integrated into the logic, ensuring proper interfacing, reliable system operation, and preventing potential faults or malfunctions.

Successful Energization and Testing

INTECH's team ensured a seamless and safe commissioning process through a comprehensive approach. This included executing thorough pre-energization inspections, validating the project operation philosophy, and proactively resolving wiring issues, incorrect parameterization in protection relays, and control schematic discrepancies. Through comprehensive troubleshooting, INTECH successfully completed load run tests independently, demonstrating expertise and eliminating the need for OEM support, resulting in safe and reliable substation operation.

Safety

Commissioning complex electrical systems, especially in an environment involving LV/MV electrical equipment and multiple contractors, presents significant safety challenges. The inherent risks associated with live electrical work, coupled with the potential for miscommunication and coordination issues among various teams, can lead to serious accidents. Specifically, this project involved complex LV/MV equipment, demanding meticulous handling and adherence to strict safety protocols. The presence of numerous contractors increased the complexity of coordinating safe work practices. Moreover, the safety of the equipment itself was a critical concern. Potential operational failures due to improper handling or inadequate safety systems could result in significant downtime and financial losses. Therefore, ensuring a safe working environment and protecting both personnel and equipment was critical.

Solution

INTECH ensured the safety of personnel and equipment through a multi-faceted approach, emphasizing prevention and rigorous adherence to safety protocols.

Personnel Safety:

• Comprehensive Risk Assessment: Before starting any work, INTECH conducted thorough risk assessments to identify potential hazards associated with the electrical systems, site conditions, and project activities.
• Strict Personal Protective Equipment (PPE) Policy: INTECH mandated the use of appropriate PPE, including insulated gloves, flame-resistant clothing, safety boots, and face shields, to protect personnel from electrical hazards like shocks and arc flashes. Regular inspections ensured PPE integrity.
• Robust Permit-to-Work (PTW) System: A structured PTW system was implemented to control and authorize high-risk activities. This system ensured that all necessary safety precautions were in place before work commenced, including isolation and de-energization procedures.
• Regular Toolbox Talks (TBTs): Daily TBTs were conducted to reinforce safety awareness, discuss task-specific hazards, and review safe work practices. These meetings fostered a culture of safety and ensured that all personnel were informed and prepared.
• Dedicated Safety Personnel: Experienced safety personnel were deployed on-site to monitor compliance with safety protocols, conduct daily safety inspections, and enforce adherence to safety procedures.
• Emergency Response Planning: INTECH developed and implemented comprehensive emergency response plans to address potential incidents, including electrical shocks, fires, and other emergencies. Regular drills ensured that personnel were prepared to respond effectively.

Equipment Safety:

• Rigorous Lockout/Tagout (LOTO) Procedures: INTECH strictly adhered to LOTO procedures to ensure that electrical systems were de-energized and isolated before any maintenance or commissioning work. This prevented accidental energization and protected both personnel and equipment.
• Comprehensive Safety Systems: INTECH installed and maintained multiple integrated safety systems, including fire alarm systems, HVAC systems, and gas detection systems. These systems provided early detection and warning of potential hazards, enabling timely intervention.
• Preventive Maintenance: Regular preventive maintenance was conducted on all electrical equipment to ensure its proper functioning and prevent failures. This included inspections, testing, and calibration of critical components.
• Quality Control and Testing: INTECH implemented rigorous quality control and testing procedures to ensure that all equipment met industry standards and specifications. This included factory acceptance tests (FATs) and site acceptance tests (SATs).

Maintaining a zero-incident safety record, INTECH prioritized and proactively implemented the highest safety standards, ensuring personnel well-being and equipment protection.

Conclusion

Bringing the new processing units online swiftly was critical, as any delays would impact the client’s carbon footprint reduction efforts and the supply of much-needed electrical power to an electricity-deficient region. To ensure a reliable and efficient power distribution system?for the processing units, the client sought an experienced engineering partner—and chose INTECH for its proven expertise in electrical systems and a track record of delivering fast-paced, high-quality projects.

INTECH reaffirmed its position as a leading E-Houses provider, successfully delivering pre-tested, plug-and-play E-Houses while also taking on the complex commissioning of OEM-built substations. Leveraging advanced modelling and diagnostic tools, INTECH optimized space constraints, identified and resolved system performance gaps, and ensured a fully operational, cost-effective, and ahead-of-schedule solution with minimal on-site work.